CAREER: Ultrasonically Assisted Wire Arc Additive Manufacturing of Metal Matrix Nanocomposites for High-strength, Lightweight Structures

职业：用于高强度、轻质结构的金属基纳米复合材料的超声波辅助电弧增材制造

• 批准号: 2044526
• 负责人: Xun Liu
• 金额: $ 50.19万
• 依托单位: Ohio State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2021
• 资助国家: 美国
• 起止时间: 2021-01-01 至 2025-12-31
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2044526&HistoricalAwards=false
• 关键词: CAREER; Ultrasonically; Assisted; Wire; Arc

This Faculty Early Career Development (CAREER) grant focuses on an innovative ultrasonically assisted wire arc additive manufacturing process for fabricating metal matrix nanocomposite structures in freeform and at large scale. Metal matrix nanocomposites are a promising class of lightweight materials with superior mechanical performance attributed to well-dispersed nanoparticles within the bulk. Wire arc additive manufacturing is based on arc welding principles in which a continuously fed metal wire is melted and deposited into a desired complex shape, layer-by-layer. The process enables the direct manufacture of metal matrix nanocomposite functional parts and is advantageous in distinctly high deposition rate and low cost compared with powder-based additive manufacturing processes. This project would facilitate wide applications of metal matrix nanocomposites for lightweight structures, which improves energy efficiency, reduces fuel consumption and benefits various transportation industries, thus contributing to national economy and security. Multidisciplinary and real-world problem-based student training at different levels are well integrated into this project. Research results are transformed into multiple outreach initiatives that increase manufacturing career awareness in young generations and under-represented minorities. The virtual lab tools promote distance and continuing education. All of these contribute to development of globally competitive and diverse STEM workforce. The goal of this research is to investigate ultrasonically assisted wire arc additive manufacturing of metal matrix nanocomposites. While lightweight, high strength components are possible in these materials, achieving superior mechanical properties is challenging due to agglomeration of nanoparticles in the repeated melting cycles, solidification defects, porosity and inferior as-cast microstructure. To improve wire arc additive manufacturing, this research utilizes superimposed ultrasonic vibration to disperse the nanoparticles, refine the microstructure and minimize the defects. Specific objectives are to (1) understand the interaction of acoustic and electromagnetic fields and nanoparticle dispersions on melt pool hydrodynamics, (2) reveal coupling principles of acoustic field and nanoparticles on microstructure evolution in the repeated melting and solidification cycles, and (3) integrate data-driven and physics-based approaches for high fidelity modeling and analysis. The ultrasonically assisted wire arc additive manufacturing system is equipped with multiple sensors for online thermal-mechanical-acoustic analysis for process monitoring and control. Parts built with this hybrid process under different conditions are subject to comprehensive evaluation and multi-scale microstructure characterization. To establish relationships between process parameters, deposition profile, microstructure and mechanical properties, emerging data science tools are utilized, which are regularized by physics-based molten pool, solidification and phase transformation models. This modeling framework enables computational and data efficient tools for analyzing complex nonlinear physics involved in various manufacturing processes.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

这项教师的早期职业发展（职业）赠款重点介绍了一种创新的超声辅助线弧添加剂制造工艺，用于在Freeform和大规模上制造金属基质纳米复合材料结构。金属基质纳米复合材料是一类有前途的轻质材料，具有出色的机械性能，归因于散装内部分散的纳米颗粒。线弧添加剂制造基于电弧焊接原理，在该原理中，连续喂养的金属线融化并沉积到所需的复合形状，逐层。该过程使金属基质纳米复合材料功能零件的直接生产具有明显高的沉积速率和低成本相比，与粉末基添加剂制造工艺相比，这是有利的。该项目将促进金属基质纳米复合材料的广泛应用，以提高能源效率，降低燃油消耗并受益于各种运输行业，从而有助于国民经济和安全。在不同级别的多学科和现实世界中基于问题的学生培训已很好地整合到该项目中。研究结果被转变为多项外展计划，以提高年轻一代人和代表性不足的少数群体的制造业意识。虚拟实验室工具促进距离和继续教育。所有这些都有助于发展全球竞争和多样化的STEM劳动力。这项研究的目的是研究金属基质纳米复合材料的超声辅助线弧添加剂。尽管在这些材料中可以轻巧，高强度成分，但由于纳米颗粒在反复的熔化周期中，固体缺陷，孔隙率和下型微观结构中的纳米颗粒聚集，因此实现了上等的机械性能。为了改善电弧添加剂制造，这项研究利用叠加的超声振动来分散纳米颗粒，完善微观结构并最大程度地减少缺陷。特定的目标是（1）了解融化池流体动力学上声学和电磁场和纳米粒子分散的相互作用，（2）揭示了在重复熔融和固体循环中的微观场和纳米结构进化的偶联原理，以及（3）集成数据基于数据源和物理学模型，以实现数据融化和固体的模型。超声辅助的电弧添加剂制造系统配备了多个传感器，用于在线热机械声音分析，用于过程监测和控制。在不同条件下用这种混合过程建造的部分受到全面评估和多尺度的微观结构表征。为了在过程参数，沉积概况，微观结构和机械性能之间建立关系，利用了新兴的数据科学工具，这些工具通过基于物理的熔融池，固化和相变模型进行了正规化。该建模框架可实现计算和数据有效的工具，用于分析各种制造过程中涉及的复杂非线性物理学。该奖项反映了NSF的法定任务，并认为使用基金会的知识分子和更广泛的影响审查标准，认为值得通过评估来支持。

项目成果

Experimental Analysis of Metal Inert Gas Based Wire Arc Additive Manufacturing of Aluminum Nanocomposite AA7075

金属惰性气体基电弧增材制造铝纳米复合材料AA7075的实验分析

• DOI: 10.1115/msec2022-85413
• 发表时间: 2022
• 期刊: ASME 2022 17th International Manufacturing Science and Engineering Conference
• 作者: Darnell, Mason;Harwig, Dennis;Liu, Xun
• 通讯作者: Liu, Xun

Ultrasonic effects with different vibration positions on gas tungsten arc wire additive manufactured aluminum nanocomposite

不同振动位置超声对气体钨极电弧丝增材制造纳米铝复合材料的影响

• DOI: 10.1016/j.jmapro.2023.09.043
• 发表时间: 2023
• 期刊: Journal of Manufacturing Processes
• 影响因子: 6.2
• 作者: Wang, Tianzhao;Liu, Xun;Darnell, Mason
• 通讯作者: Darnell, Mason

Ultrasonic effects on gas tungsten arc based wire additive manufacturing of aluminum matrix nanocomposite

• DOI: 10.1016/j.matdes.2022.110393
• 发表时间: 2022-01
• 期刊: Materials & Design
• 影响因子: 8.4
• 作者: T. Wang;V. Mazánová;Xun Liu

Ultrasonically assisted hot-wire arc additive manufacturing process of AA7075 metal matrix nanocomposite

超声辅助热丝电弧增材制造AA7075金属基纳米复合材料

• DOI: 10.1016/j.jallcom.2022.168298
• 发表时间: 2023
• 期刊: Journal of Alloys and Compounds
• 影响因子: 6.2
• 作者: Wang, Tianzhao;Kang, Jiarui;Darnell, Mason;Liu, Xun
• 通讯作者: Liu, Xun